Fence assembly with &#39;two-piece&#39; rail

ABSTRACT

A picket fence system using two part parallel rails to enclose and secure intermittent pickets, which can be assembled without screws or fasteners is described.

BACKGROUND

This invention relates to a fencing system, and more particularly to a two-piece rail system, which can be incorporated into a picket fence. A picket fence comprising a pair of spaced apart parallel rails, supported by horizontal posts, and having a plurality of pickets incorporated between the rails.

Picket fences are found in a variety of uses and construction types. Picket fences made of metal or plastic have a number of performance features, which make them especially desirable, including low maintenance, durability, and aesthetics. Typically the pickets of the fence are adhered to rails running nearly parallel to the ground via welding (metal) or other post attachment technique. This invention details a two-piece rail for a picket fence, and a construction method for this fence system, which can easily be constructed at a construction site. The pickets of the fence are incorporated into the system without the need for welding, or other attachment hardware and can be done by a professional or homeowner.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:

FIG. 1 shows a cross sectional view of the two pieces of the two-piece fence rail

FIG. 2 shows a longitudinal view of one piece of the two-piece rail

FIG. 3 shows the incorporation of a picket into the two-piece rail

FIG. 4 shows a diagram of the assembled two-piece fence rail incorporated into a picket fence

DETAILED DESCRIPTION

Referring now to the figures, and in particular to FIG. 1, there is shown an enlarged cross-sectional view of the two pieces 100 and 200 of the two part fence rail. In a preferred embodiment, the second piece 200 of the two part rail is fabricated identical to the initial piece 100. Piece 100 and piece 200 of the two part rail are fabricated in such a manner that first piece 100 and second piece 200 can be interlocked to form rail 300 also shown in FIG. 1. Utilization of a two part rail in which pieces 100/200 are identical, allows for a reduction in cost and ease of construction. These cost reductions include extrusion tooling, manufacturing costs, and inventory carrying costs.

Again referring to FIG. 1, the key design features of the individual rail pieces 100/200 can be seen. The terminal edges 110/120 and 210/220 of the cross section of the fence rail component 100/200 are designed such that the individual edges will interlock with their opposing edge from another rail component. That is terminal edge 110 will interlock with terminal edge 220; and conversely terminal edge 120 will interlock with terminal edge 210. The terminal edges 110/120 and 210/220 typically include a thickened bead of extruded material, to facilitate the rail-rail interlock of the two rail components 100/200 and to provide rigidity in the length direction of the component. Protrusions 130/230 are positioned on the components 100/200 such that they will facilitate the interlocking of the terminal edges and reduce the ability of the interlocked edges to move and or unfasten. Additionally a screw boss component 150/250 is included to allow for the rail to be affixed to a terminal fence post and to allow for seating of a fence picket into the rail system.

In one embodiment, the two part rail is made from extruded aluminum. Other material which may be used include extruded thermoplastic polymers. Typically the materials used for the two part rail will also be used in the production of the other components of the fence system.

Now referring to FIG. 2, there is shown a longitudinal view of piece 100 of the two part rail. Incorporated into the rail section 100 at regular intervals are picket cutouts 101. These cutouts are typically spaced regularly along the rail at standard intervals for pickets in a picket fence system (i.e. 4 inches). The dimensions of the cutout 101 are such that they will allow a specifically sized picket 400 to be incorporated through the rail, while not affecting the dimensional stability of the rail 300 or the individual components 100/200.

The incorporation of picket 400 into the cutout 101 of the rail section 100 is aided by dimples and/or tabs 401 in the picket 400. These dimples/tabs 401 allow the picket 400 to be seated into the screw boss 150 of the rail section 100. Additionally the seating of these dimples/tabs 401 in the screw boss 150 secure the picket into the completed rail 300 in such a manner that the picket 400 is secured.

The dimples/tabs 401 are placed on the picket 400 at a distance from the terminal ends of the picket 400 that allow for the two part rail to be incorporated into the picket fence system at whichever height fits the design requirements of the fence system. In a typical fence system, two rails 300 are incorporated into the fence system. It can be seen that in the invention described, any number of rails 300 could be incorporated into the fence, only requiring the appropriate number of matching dimple/tab pairs 401 be incorporated in the pickets 400.

Referring now to FIG. 3, there is shown the incorporation of a picket 400 in an assembled two piece rail 300. It can be seen that the tabs 401 project out from the picket 400 and lodge in the two screw-boss' 150/250 of the rail 300. The seating of these tabs 401 in the two screw-boss' 150/250 of the rail 300 secure the picket 400 in the rail 300. By securing the picket 400 to the rail 300 using this method, external hardware such as screws can be eliminated for securing the picket. This enhances the ease of assembly and aesthetics of the fence.

Referring now to FIG. 4, the incorporation of the two part rail 300 and the pickets 400 into a fence section 500 can be seen. The two part rail 300, and the pickets 400 to be incorporated therein, are designed such that multiple sections of the fence system can be easily assembled with minimal tools required at the job site. The length of the rail components 100/200 and thus the assembled rail 300 and fence section 500 is variable and will typically be chosen for aesthetic and ease of assembly considerations. Additionally the design of the individual rail components 100/200 of the fence rail 300, allow for the easy construction of the section 500 via laying one of the individual rail components 100/200 for each rail 300 to be incorporated onto the ground, then lying the pickets 400 into the picket cutouts 101. The opposing component 100/200 of the fence rail 300 is then snapped into place, locking in the placed pickets 400. The completed fence section 500 can then be easily lifted into place and secured to the fence posts 600.

The fence sections 500 can be easily assembled into a fence system by attachment of the individual sections 500 to fence posts 600 located at regular intervals in the fence system. This attachment can be, but is not limited to, attachment via screws through the post 600 and into the rail component 100/200 at the screw boss 150/250. The design structure of the individual fence sections 500 also allow for the individual sections to easily be racked at an angle of up to fifty degrees. That is to allow the use of the fence system on an up or down grade of up to fifty degrees with no substantial loosening of the fence parts or undue torque on the fence components. 

1. A picket fence which includes: a. A two-piece rail, which can be snapped together to surround and secure a fence picket. b. Pickets c. Posts to which the two piece rail system are attached.
 2. The picket fence described in claim 1, in which the fence is constructed of extruded aluminum.
 3. The picket fence described in claim 1, in which the fence is constructed of a thermoplastic polymer.
 4. The two piece rail system in claim 1, in which the two pieces of the rail are essentially identical in cross section.
 5. A two piece rail in which the two pieces can be snapped together to surround and secure a fence picket.
 6. The two piece rail described in claim 5, in which the rail pieces are constructed of extruded aluminum.
 7. The two piece rail described in claim 5, in which the rail pieces are constructed of thermoplastic polymer.
 8. The two piece rail described in claim 5, in which the rail pieces are essentially identical in cross section.
 9. The process of constructing a picket fence, which includes the steps of: a. Placing one rail of a two-part rail on a flat surface. b. Placing pickets into prepunched sections of the rail. c. Locking the pickets into place via attachment of the second part of the two part rail around the picket. d. Incorporation of the site assembled fence pieces into a fence system via attachment to posts which are secured in the ground. 